U-shaped housing and cover concept for plate fin heat exchangers

ABSTRACT

A housing for a heat exchanger comprising includes a first housing portion having and a second housing portion. The first housing portion has a U-shaped cross-section. The second housing portion cooperates with the first housing portion to define a chamber. The chamber receives a heat exchange assembly. The second housing portion is configured as a plate.

FIELD OF THE INVENTION

The invention relates to a heat exchanger for a vehicle, and more particularly, to a housing configuration for a heat exchanger.

BACKGROUND

As is commonly known, it is desirable for air entering an engine of a vehicle to be cooled, especially after exiting a turbocharger or a supercharger, because cooler air will have an increased density that maximizes an efficiency of the engine. In certain situations, the cooling of the air may also facilitate engine management and eliminate pre-detonation of the air and a fuel prior to a timed spark ignition. Additionally, the cooling of the air militates against excessive wear or heat damage to an engine block of the engine.

Heat exchangers such as water-cooled charge air coolers (WCAC) can be used in the vehicle to cool the air that has been compressed by the turbocharger or the supercharger prior to entering the engine. Typically, for application specific needs such as space constraints in a vehicle, for example, WCACs utilize a coolant from one or more sources and may include a heat exchange core with plates interposed between fins.

Typically, the core of the heat exchanger is disposed within a housing. The housing is coupled to an inlet tank configured for receiving air to be cooled within the heat exchanger and an outlet tank configured for conveying the cooled air from the heat exchanger. Disadvantageously, however, the housing may be complex or formed from multiple components such as greater than or equal to three components. The numerous components increase manufacturing and assembly costs. Additionally, the multiple components are susceptible to leakage at the joints of the multiple components forming the housing.

Accordingly, there exists a need in the art for a simple housing for a heat exchanger formed from minimal components that minimizes manufacturing and assembly costs and minimizes leakage.

SUMMARY OF THE INVENTION

In concordance with the instant disclosure, a simple housing for a heat exchanger formed from minimal components that minimizes manufacturing and assembly costs and minimizes leakage is discovered

According to a first embodiment of the disclosure, a housing for a heat exchanger is disclosed. The housing has a first housing portion having a U-shaped cross-section and a second housing portion cooperating with the first housing portion to define a chamber receiving a heat exchange assembly. The second housing portion is configured as a plate.

According to another embodiment of the disclosure, a core assembly for a heat exchanger is disclosed. The core assembly includes a two-component housing including a first housing portion and a second housing portion cooperating to define a chamber with a first open end and a second open end. A heat exchange assembly is received in the chamber.

According to yet another embodiment of the disclosure, a heat exchanger for a vehicle is disclosed. The heat exchanger includes a core assembly having a first open end and a second open end. The core assembly includes a housing receiving a heat exchange assembly. The housing is formed from a substantially U-shaped first housing portion and a substantially planar second housing portion. A first tank is coupled to the first open end of the core assembly. A second tank is coupled to the second open end of the core assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view of a heat exchanger according to an embodiment of the disclosure;

FIG. 2 is an assembled bottom perspective view of a core assembly of the heat exchanger of FIG. 1;

FIG. 3 is an exploded bottom perspective view of the core assembly of FIG. 2;

FIG. 4 is a left side elevational view of the core assembly of FIGS. 2-3, wherein the core assembly includes a header; and

FIG. 5 is a left side elevational view of the core assembly of FIGS. 2-3, wherein the header is not shown.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description and appended drawings describe and illustrate various embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner. In respect of the methods disclosed, the steps presented are exemplary in nature, and thus, the order of the steps is not necessary or critical. As used herein, the term “substantially” means “mostly, but not perfectly” or “approximately” as a person skilled in the art would recognize in view of the specification and drawings.

FIG. 1 illustrates a heat exchanger 10 according to an embodiment of the disclosure. As illustrated, the heat exchanger 10 is configured as an intercooler such as a water-cooled charge air cooler, for example. However, it is understood the heat exchanger 10 can be configured as any type of heat exchanger commonly employed in vehicle systems such as used for a air-cooled charge air cooler, a tube-type heat exchanger, a radiator, an oil cooler, or other heat exchanger now known or later developed. The heat exchanger 10 includes an inlet tank 12 and an outlet tank 14 for respectively receiving and conveying air flowing from an air circuit of a vehicle. The heat exchanger 10 further includes conduits 17 which are in fluid communication with openings, such as fluid inlets and outlets, for conveying fluid to or conveying fluid from the heat exchanger 10. For example, the fluid can be a coolant, a refrigerant, water or any other fluid configured for exchanging heat with the air flowing through the heat exchanger 10.

As shown in FIGS. 2-5, the heat exchanger 10 further includes a core assembly 15 disposed intermediate the inlet tank 12 and the outlet tank 14. The core assembly 15 has a first open end 15 a configured to receive the air from the inlet tank 12 flowing through the heat exchanger 10. A second open end 15 b opposes the first open end 15 a and is configured to convey the air flowing through the heat exchanger 10 to the outlet tank 14. The core assembly 15 includes a heat exchange assembly 16 configured to transfer heat between the air flowing through the heat exchanger 10 and the fluid . In certain embodiments, such as shown, the core assembly 15 further includes a pair of headers 19. Each of the headers 19 is configured to facilitate coupling the inlet tank 12 and the outlet tank 14, respectively, to the core assembly 15. However, it is understood the core assembly 15 can be coupled to each of the inlet tank 12 and outlet tank 14 directly without the headers 19. Although not shown, other components such as seals can be positioned intermediate respective ones of the inlet tank 12 and the outlet tank 14 and the core assembly 15, if desired.

The heat exchange assembly 16 is disposed in a housing 18 of the core assembly 15. The heat exchange assembly 16 includes a plurality of stacked, substantially parallel plate assemblies 22. The plate assemblies 22 are interposed between a plurality of substantially parallel fins 20. Each of the plate assemblies 22 defines at least one flow channel (not shown) for receiving the fluid from at least one external source. It is understood, other fluid conveying mechanisms can be employed instead of the plate assemblies 22. For example, tubes can be employed instead of the plate assemblies 22. Other fluid conveying mechanisms can be employed as desired.

The housing 18 shown is a multi-component housing formed from a pair of components designated as a first housing portion 24 and a second housing portion 26. The first housing portion 24 and the second housing portion 26 cooperate with each other to define a chamber for receiving the heat exchange assembly 16. It is understood other housing configurations can be used to enclose and receive the heat exchange assembly as desired. The first housing portion 24 has a substantially U-shaped cross-section including a first wall 28 and a pair of second walls 30. The second walls 30 extend outwardly from an inner surface 54 of the first wall 28 at opposing sides of the first wall 28 and substantially perpendicular to the first wall 28. The second walls 30 extend substantially parallel to a direction of flow of the air through the heat exchanger 10, as indicated by an arrow. The second walls 30 form closed sides of the core assembly 15.

A pair of flanges 34 is coupled to the first housing portion 24 of the housing 18, wherein a first one of the flanges 34 is formed at the first open end 15 a and a second one of the flanges 34 is formed at the second open end 15 b. The flanges 34 frame or define a portion of the openings at the respective one of the first open end 15 a and the second open end 15 b. In the embodiment illustrated, the flanges 34 are substantially U-shaped to correspond in shape with the first housing portion 24. The flanges 34 can be formed separate from and coupled to the first housing portion 24 by attachment means such as a brazing or welding process, for example, or the flanges 34 can be integrally formed with the first housing portion 24. Each of the flanges 34 cooperates with a respective lip 46 formed on the second housing portion 26 of the housing 18, which will be described in further detail hereinbelow, to form a frame or support 48 configured for engagement with the header 19 or one of the tanks 12, 14.

The flanges 34 have a substantially flat engagement surface 36 to facilitate engagement of the flanges 34 to the header 19 or one of the tanks 12, 14 for a welding or a brazing operation, for example. In the embodiment illustrated, the outer perimeter 38 of the flanges 34 extends outwardly from an outer surface 25 of the first housing portion 24 of the housing 18. Tabs 40 are formed along the perimeter 38 of the flanges 34 to facilitate alignment and positioning of the header 19 or one of the tanks 12, 14 to the housing 18 prior to the welding or the brazing operation. The tabs 40 extend substantially perpendicular to and outwardly from the engagement surface 36 of the flanges 34. Three of the tabs 40, one at each lateral side of each of the flanges 34 and one at a portion of each of the flanges 34 extending from the first wall 28 of the first housing portion 24, are shown. However, more than three or fewer than three tabs 40 can be included if desired.

A plurality of apertures 32 is formed through the first wall 28 of the first housing portion 24. The apertures 32 are configured for providing fluid communication between the conduits and the heat exchanger 10. The apertures 32 provide fluid communication of the fluid from the external fluid source to the chamber formed by the first housing portion 24 and the second housing portion 26. It is understood the apertures 32 can be formed in other portions of the housing 18, as desired, such as in the second walls 30 or the second housing portion 26, for example.

The second housing portion 26 of the housing 18 is configured as a substantially planar plate with the lip 46 disposed at each of opposing ends of the second housing portion 26. Each of the lips 46 extends outwardly from a surface 50 of the second housing portion 26 substantially perpendicular to the surface 50. As mentioned hereinabove, each of the lips 46 cooperates with a respective one of the flanges 24 to form the frame 48. The second housing portion 26 has a width slightly less than the width between the inner surfaces 54 of the second walls 30 of the first housing portion 24, wherein side edges of the second housing portion 26 abut the inner surfaces 54 of the second walls 30 of the first housing portion 24. The first housing portion 24 has a length substantially equal to a length of the second housing portion 26.

The frame 48 is substantially rectangular to engage the header 19 that is substantially rectangular or the tank 12, 14 that is substantially rectangular. However, the frame 48 can have other shapes as desired to facilitate engaging with the header 19 and/or tank 12, 14 having alternate shapes.

The tabs 40 facilitate alignment and engagement of the header 19 or the tank 12, 14 to the frame 48, and consequently to the core assembly 15. Once aligned and engaged with the core assembly 15, the header 19 or the tank 12, 14 is secured to the frame 48 by a coupling means such as a brazing process, a welding process, or a crimping process. Although, other coupling means such as fasteners, bolts, screws, clamps, or other coupling means can be contemplated, if desired.

The components of the housing 18 (i.e. the first housing portion 24 and the second housing portion 26) can be formed from any material or process as desired. In one example, the first housing portion 24 and the second housing portion 26 are formed from aluminium by a stamping or casting process. In another example, the first housing portion 24 and the second housing portion 26 of the housing 18 are formed from a plastic material by a plastic forming process such as a molding process or extrusion process. Although, it is understood the first housing portion 24 and the second housing portion 26 of the housing 18 can be formed from any material or any process as desired. The first housing portion 24 is coupled to the second housing portion 26 by coupling means such as a brazing process, a welding process, or a crimping process. Although bolts, screws, clamps, or other coupling means can be contemplated, if desired.

To assemble the core assembly 15, the heat exchange assembly 16 is received in the first housing portion 24, wherein the first housing portion 24 partially covers the heat exchange assembly 16. The second housing portion 26 cooperates with the first housing portion 24 to form the housing 18 to enclose the heat exchange assembly 16 to form the housing 18 and define the first open end 15 a and the second open end 15 b of the core assembly 15. The side edges of the second housing portion 26 engage respective ones of the inner surfaces 54 of the second walls 30 of the first housing portion 24. The lips 46 of the second housing portion 26 align with the flanges 34 to form the frames 48. Once the second housing portion 26 is positioned in cooperation with the first housing portion 24, the first housing portion 24 is coupled to the second housing portion 26 by the coupling means.

According to one embodiment of the disclosure, the tanks 12, 14 are directly coupled to the core assembly 15 by the coupling means. In another embodiment, the headers 19 are directly coupled to the core assembly 15 by the coupling means and disposed intermediate the tanks 12, 14 and the core assembly 15. The tabs 40 are configured to align and engage the tanks 12, 14 or the headers 19 prior to coupling. Once aligned and engaged, the tanks 12, 14 or the headers 19 can then be brazed, welded, or otherwise coupled by the coupling means to the frames 48.

Advantageously, the heat exchanger 10 according to the present disclosure minimizes the number of components required to form the housing 18 of the heat exchanger 10, such as less than four components, and more specifically, such as two components as described herein. Additionally, because only two components form the housing 18, there is less brazing, welding, or coupling interfaces between the components of the housing 18 than prior art housings for heat exchangers. Consequently, there are less coupling interfaces leading to possible leakage. Furthermore, the heat exchanger 10 of the present disclosure minimizes manufacturing costs and complexity.

From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions. 

What is claimed is:
 1. A housing for a heat exchanger comprising: a first housing portion having a U-shaped cross-section; and a second housing portion cooperating with the first housing portion to define a chamber receiving a heat exchange assembly, the second housing portion configured as a plate.
 2. The housing of claim 1, wherein the first housing portion has a flange extending outwardly from an outer surface of each of opposing ends thereof.
 3. The housing of claim 2, wherein the second housing portion has a lip extending outwardly from a surface of each of opposing ends thereof.
 4. The housing of claim 3, wherein the flanges of the first housing portion and the lips of the second housing portion cooperate to define a frame configured for coupling to at least one of a header and a tank.
 5. The housing of claim 4, wherein a tab extends outwardly from an engagement surface of the frame.
 6. The housing of claim 1, wherein the first housing portion and the second housing portion are formed from one of aluminum and plastic.
 7. The housing of claim 1, wherein the first housing portion is coupled to the second housing portion by one of a brazing process, a welding process, and a crimping process.
 8. A core assembly for a heat exchanger comprising: a two-component housing including a first housing portion and a second housing portion cooperating to define a chamber with a first open end and a second open end; and a heat exchange assembly received in the chamber.
 9. The core assembly of claim 8, wherein the heat exchange assembly includes a plurality of plate assemblies interposed between a plurality of fins.
 10. The core assembly of claim 8, wherein the first housing portion has a substantially U-shaped cross-section.
 11. The core assembly of claim 8, wherein the second housing portion is substantially planar.
 12. The core assembly of claim 8, wherein the first housing portion has a flange extending outwardly from a surface thereof at an end of the first housing portion.
 13. The core assembly of claim 12, wherein the second housing portion has a lip extending outwardly from a surface thereof, the lip cooperating with the flange to define a frame configured for coupling to one of a header and a tank of the heat exchanger.
 14. The core assembly of claim 12, wherein the first housing portion has a tab extending outwardly from an engagement surface of the flange, the tab configured to align one of a header and a tank of the heat exchanger.
 15. The core assembly of claim 8, wherein the first housing portion and the second housing portion are formed from one of aluminum and plastic.
 16. A heat exchanger for a vehicle comprising: a core assembly having a first open end and a second open end, the core assembly including a housing receiving a heat exchange assembly, the housing formed from a substantially U-shaped first housing portion and a substantially planar second housing portion; a first tank coupled to the first open end of the core assembly; and a second tank coupled to the second open end of the core assembly.
 17. The heat exchanger of claim 16, further comprising a header disposed intermediate each of the first tank and the core assembly and the second tank and the core assembly.
 18. The heat exchanger of claim 17, wherein at least one of the header, the first tank, and the second tank is one of welded, brazed, and crimped to the core assembly.
 19. The heat exchanger of claim 16, wherein the first housing portion has a flange disposed at each end thereof, the flange extending outwardly from an outer surface thereof, wherein the second housing portion has a lip disposed at each end thereof, the lip at each end extending outwardly from a surface of the second housing portion, and wherein the flange at each end respectively cooperates with the lip at each end to form a frame configured to engage one of the first tank, the second tank, and a header.
 20. The heat exchanger of claim 19, wherein a plurality of tabs extends outwardly from an engagement surface of the flange, the tabs configured to align one of the first tank, the second tank, and the header to the housing. 